From tensioning straps to hairpins
Wire 2026 is the platform for experiencing how automated wire forming technology sets new standards in terms of diversity and precision. At our booth, we will be presenting innovative, value-adding solutions on an interactive wall.
You can expect a selected repertoire of precision formed parts that demonstrate efficient and process-optimized parts manufacturing. The modularly designed Bihler machines are flexibly equipped with the appropriate tooling technology so that even complex productions from painted flat wire can be realized economically.
We look forward to showing you the interaction of engineering artistry and automation expertise in our modular Bihler machines.
Come and visit us – we look forward to seeing you!
Mathias Bihler and the entire Bihler team
Highlights at the Wire
Springs and wire parts are where it all began for Bihler - more than 70 years ago. Since then we have successfully implemented thousands of production solutions for customers in various branches.
The advantages of Bihler technology:
- The simultaneous forming operations enable very high production speeds.
- Forming from the inside out eliminates twisting and torsional effects, and guarantees exact dimensional accuracy.
- In addition to forming, the Bihler machines offer the capability to coin, cut, weld and laser mark the wire parts.
High-precision wire forming parts
We will be demonstrating at our booth the production of tension strap hangers made of 5 mm thick steel wire. The Bihler GRM-NC, with its radial forming tool, impresses with decisive advantages.
- Very high production speeds
The simultaneous forming operations enable production speeds of up to 100 parts per minute. In economic terms, Bihler technology thus offers clear advantages for medium to very large batch sizes. - Better quality
Plus, forming from the inside out eliminates twisting and torsional effects, and guarantees exact dimensional accuracy and top quality products. - Additional processes
And, in addition to the ten forming operation, the tension strap hangers are also coined and cut. Bihler technology also offers interfaces for other processes such as welding, laser marking, etc.
All-in-one solution for hairpins
The BM-HP 3000 servo production system opens up new dimensions in the mass production of all common types of hairpins. Benefit from very high cycle rates up to 120 parts per minute along with simple and fast variant changes "on the fly".
The compact servo system, with its modular processing units, contains all the process steps for this production.
- multi-stage straightening and highly dynamic, slip-free feeding of the wire
- precise cutting to the straight length
- NC-controlled mechanical stripping of the coating
- simultaneous chamfering of the pin ends
- 2D pre-bending in a parallel-cycle swivel-bending process
- 3D die-bending of the final head shape
- removal and mono-component storage
Precise control and flexible scalability
The precise control of the servo units via the central VariControl VC 1 guarantees one hundred percent reproducibility and top quality of the hairpins. The flexible scalability allows you to adapt the machine to future task.
Production simplified through compatibility
All machines in the modular series have standardized interfaces and a zero-point clamping system with hydraulic clamping functions. This makes them fully compatible with each other in terms of the linear stamping and forming tools used. A direct assignment of tool to machine is completely eliminated.
Simplified, stable production planning and order planning
Standardized, uniform machine interfaces guarantee machine-independent application of the forming tools. The fixed assignment of particular tools to particular machines is not required. As a result, production planning time and effort can be greatly reduced, more efficient order planning and sequencing can be established, and capacity bottlenecks can be eliminated.
Machine-independent tool design
The uniform design guideline for stamping and forming tools enables the user to design the tools independently of the machine. By dramatically reducing the number of staff required to participate in the design process, the independent design capability offers the user a more efficient use of their design engineers‘ expertise, and conserves valuable design time and capacity.
Flexible tool technology
These five machines provide maximum flexibility by allowing you to use the exact tool technology you need - whether it is the highly-standardized LEANTOOL technology, or any parts from it, or your own linear tool standard. Simply follow the guidance provided by the product line - the tools can be set up quickly and easily, and they are fully compatible with your machine park.
Digital transparency at all times
Each of these five machines is equipped, as a standard feature, with OPC UA interfaces, which form the bases for future applications in the IoT, M2M and I4.0. The interfaces can also be used to transfer machine conditions to a higher-level MES or ERP system, or to connect to the “Bihler Analysis Tool” software tool in plug & play operation. The digital tools do not require any customizing, yet they provide clearly-presented features offering production analyses, as well as order and information management.
Simplified and efficient maintenance
The five machines utilize many identical components. For example, the GRM-NC, the LM 2000-NC, and the BIMERIC BM are all equipped with the same servo slide units, the same quick tool clamping system, and the same material feed. The use of identical components across the board increases machine availability time, and decreases the need for spare part maintenance inventories. The net result? Efficient and simplified maintenance that serves to minimize effort, time, and cost.
Optimized work for your employees
Uniformity, standardization, and consistency are reflected in all aspects of the Modular Series, which makes the work process more clear-cut and more straightforward for your employees: uniform operating routines for machine control; a standardized cross-machine design guideline for tool design, a large number of identical components for maintenance; and a uniform setup system. These many features all work together - to ensure that you always have the right machines for job planning - and to ensure that your employees work in an optimal production setting.
The Bihler Modular Series offers new production possibilities, and even more effective ways to meet ever-increasing production demands. Consisting of five high-performance, highly standardized models, these modular machines are fully compatible with one other with respect to the linear forming tools that are used, and they feature uniform interfaces in the forming area. As a result, the variety of different solutions and machines is significantly reduced. Uniformly designed forming tools can now be operated simply and independently of the machine in accordance with the “plug & produce” principle.
FORMING
Tool modules with the corresponding interfaces
- Simple
- Always ready for setup
- Reproduced setup procedures
Tool interface = machine interface
- Compatible stamping and forming tools (linear tools)
- A suitable machine - whatever the task
- Consistency and ease of use
Full flexibility within the tool modules
- You decide the design - according to the task
- Individual to highly standardized modules
- You have all the freedom at any time
STAMPING
Meusburger standard cutting frames
Compatible with Meusburger standard cutting frames SBP 400 and SBH 400
You can choose which Bihler machine is right for you. Our machines meet all of the requirements of the production world, whether it be small-, medium- or large-batch sizes, or low value added, or high value added by way of additional processes. Each of our five machines is compatible with all of the others. All use uniformly designed linear forming tools that offer great flexibility, and can be quickly reused or relocated, or, if necessary, they can be modified, depending on the product life cycle of the components. Each of the five machines provide all of the advantages of the full Modular Series.
GRM-NC
Small and medium series, using different tooling technologies
Very quick setup, servo-controlled universal machine. The GRM-NC is highly flexible, and can be used with different tool technologies, such as the adaptation of GRM stock tools (radial and linear), LEANTOOL Radial, and LEANTOOL Linear.
LM 2000-NC
Small and medium series, with linear tools
Very quick setup, servo-controlled production machine with a total machining length of 2,000 mm, and cycle rates of up to 250 per minute. In addition to forming, additional processes can be integrated, such as contact welding, thread forming, and screw insertion.
BIMERIC MODULAR
Forming + additional processes, through to assembly
Modular servo-controlled production machine. The BIMERIC has the ability to carry out many processes in addition to forming - whether they are an extension with joining processes (e.g., welding, thread cutting, screw insertion), or an orderly placement of the components in trays, or a complete assembly of a sheet metal part. All automated control functions are available.
LM 2000-KT
Small and large series, with linear tools
High-performance, cam-controlled production machine with a total machining length of 2,000 mm, and cycle rates of up to 500 per minute. In addition to forming, additional processes can be integrated, such as contact welding, thread forming, and screw insertion.
Highspeed-Machine
Large- to high-volume series
High-performance, cam-controlled production machine offering maximum cycle rates for high-volume production. The tools are backward compatible (in terms of speed) to the entire Modular Series. (Currently in pre-development)
Location
Bihler at the Wire 2026
13. - 17.04.2026
Düsseldorf
Hall 10 / Stand E59
Address for navigation system:
Am Staad (Stockumer Höfe)
D-40474 Düsseldorf
Contact
Claudia Wismath
(Event Managerin)
Otto Bihler Maschinenfabrik GmbH & Co. KG
Lechbrucker Str. 15
87642 Halblech
Germany
+49 8368 18-212
claudia.wismath@bihler.de